Nothern Lights M843JK User manual

Brand: Nothern Lights

Model: M843JK

Category: Power generators

Type: User manual

This manual is also suitable for

OPERATOR’S

MANUAL

OPERATOR’S

MANUAL

O843K

For Models

M843JK, M843NK, NL843NK

Diesel engine exhaust and some of its constituents

are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

— CALIFORNIA —

Proposition 65 Warning:

Northern Lights

4420 14th Avenue N.W.

P.O. Box 70543

Seattle, WA 98107

Tel: (206) 789-3880

Fax: (206) 782-5455

the Northern Lights logo are trademarks of

Alaska Diesel Electric, Inc.

Printed in U.S.A.

PART NO.: O843K 05/03

O843K 05/03

Read this operator's manual thoroughly before starting to operate your equipment.

This manual contains information you will need to run and service your new unit.

Proprietary Information

This publication is the property of Alaska Diesel Electric, Inc.

It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric, Inc.

OPERATOR'S MANUAL

for Models

M843JK, M843NK, and NL843NK

Table of Contents

INTRODUCTION ......................................................2

Models Included ...................................................2

Model Numbers....................................................2

Serial Numbers .....................................................3

WARRANTY ..............................................................3

SAFETY RULES .......................................................3

COMPONENT LOCATIONS

M843JK and M843NK Marine Generator ...........4

NL843NK Industrial Generator ...........................5

CONTROL PANELS

Northern Lights Generator Sets......................6 - 7

OPERATING PROCEDURES

Break-in Period ....................................................8

Before Starting .....................................................8

Starting .................................................................8

Operating ..............................................................8

Stopping ...............................................................8

Shutdowns and Alarms.........................................9

Spare Parts............................................................9

SERVICING SCHEDULE CHART .............. 10 - 11

SERVICING

Lubrication - General ........................................ 12

Checking Oil ..................................................... 12

Oil Changes ....................................................... 12

Changing Oil Filter............................................ 12

Air Filter ............................................................ 13

SERVICING (continued)

V-Belts .............................................................. 13

Retightening Cylinder Head Bolts .................... 13

Valve Clearances............................................... 13

Fuels - General .................................................. 14

Fuel Filters......................................................... 14

Bleeding the Fuel System.................................. 15

Injector Service ......................................... 16 - 17

Injection Pump .................................................. 17

Cooling System - General ................................. 17

Cooling System Flushing .................................. 18

Heat Exchanger (Marine) .................................. 18

Raw Water Pump .............................................. 18

Generator Ends .................................................. 18

Electrical System - General............................... 18

Glow Plugs ........................................................ 19

Booster Batteries ............................................... 19

Battery Care....................................................... 19

PTO Care........................................................... 19

Winterizing / Out-of-Service............................. 19

Exhaust Elbow................................................... 19

TROUBLESHOOTING

Electrical............................................................ 20

Engine........................................................ 21 - 23

DATA SHEETS

M843JK ............................................................. 24

M843NK............................................................ 25

WIRING DIAGRAMS

DC Electrical ............................................. 26 - 27

O843K 05/03

Introduction

Unit Identification

Servicing of marine engines and generator sets presents

unique problems. In many cases boats cannot be moved

to a repair facility. Marine engines cannot be compared

to the servicing of automobiles, trucks or even farm

equipment. Failures often occur in remote areas far

from competent assistance. Marine engines are taxed

far more severely than auto or truck engines; therefore,

maintenance schedules must be adhered to more

strictly.

Failures can begin with minor problems that are

overlooked and become amplified when not corrected

during routine maintenance.

As operator, it is your obligation to learn about your

equipment and its proper maintenance. This is not a

comprehensive technical service manual. Nor will it

make the reader into an expert mechanic. Its aim is to

aid you in maintaining your unit properly.

J / K

MODELS INCLUDED

This manual covers the operating instructions for:

M843JK marine generator sets,

M843NK marine generator sets, and

NL843NK industrial generator sets.

Fill in the model number of your unit in the blank space provided.

This will give you a reference whenever service or maintenance is required:

Additional letter

designates series

within model number

Northern Lights marine diesel generator set with

a J-series 843 engine and a PX-300K generator end

with an AVR.

M / NL

843

M843JK

Northern Lights marine diesel generator set with

an N-series 843 engine and a PX-300K generator

end.

M843NK

Northern Lights industrial generator set with an N-

series 843 engine, PX-300K generator with an AVR,

and a radiator.

=NL843NK

Model number of engine block

Bore Cylinders

84 mm 3

M - Northern Lights marine generator set

NL - Northern Lights industrial generator set

Model Numbers

Model numbers give the unit's application, block model, aspiration, and RPM:

My Northern Lights generator set MODEL number is:

O843K 05/03

Serial Numbers

Safety Rules

CAUTION: This symbol is used throughout

this book to alert you to possible danger areas.

Please take special notice of these sections.

A warranty registration certificate is supplied

with your set. It entitles the original purchaser of our

equipment to a warranty covering material

or assembly faults. The extent of coverage is described

in the Limited Warranty Statement. We recommend

that you study the statement carefully.

NOTE: If the warranty is to apply, the servicing

instructions outlined in this manual must be

followed. If further information is needed, please

contact an authorized dealer or the factory.

CAUTION: Accident reports show that careless use of engines causes a high percentage of accidents.

You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.

• Never leave engine without proper security.

• Turn the coolant tank cap slowly to relieve pressure

before removing. Add coolant only when the

engine is stopped and cool.

• Mount a fire extinguisher near engine.

• Always disconnect the battery ground strap before

making adjustments.

• Operate engines in properly ventilated areas.

• Keep trash and other objects away from engine.

• Escaping fluids under pressure can penetrate your

skin. Use a piece of cardboard or wood, not your

hands, to search for leaks.

• Avoid wearing loose clothing without a belt when

working around engines.

• Do not oil or grease engine while it is running.

• Use caution in handling fuel. Never refuel a hot or

running engine. Do not smoke while filling fuel

tank or servicing fuel system.

Your set has three serial numbers:

➀

an engine number stamped

on the block,

➁

a generator plate, and

➂

a generator set plate.

Use the serial number on the generator set plate when ordering parts

or in correspondence. The generator set plate is found on the service

side of the generator and resembles the drawing in Figure 1.

Fill in the serial number of

your unit in the box provided.

Figure 1: Generator set serial number plate.

Warranty

• Keep your hands, feet, hair and clothing away from

power-driven parts.

• Check for any loose electrical connections or faulty

wiring.

• Engines should be operated only by

knowledgeable, qualified personnel.

• Look completely around engine to make sure that

everything is clear before starting.

• Do not operate an engine that isn't in proper

working order. If an unsafe operating condition is

noted, tag the set and control panel so others will

also know about the problem.

• Provide first aid kits.

My Northern Lights generator set SERIAL number is:

O843K 05/03

1. DC Circuit Breaker

2. AC Circuit Breaker for AVR

3. Fuel Filter

4. Air Filter (inside Manifold)

5. Intake Manifold

6. Fuel Lift Pump

7. Oil Fill (2)

8. Crankcase Vent

9. Fuel Injector

10. Coolant Fill

11. Heat Exchanger End Cap

12. Injection Pump

13. Seawater Pump

14. Freshwater Block Drain

15. Fuel Inlet & Return

16. Oil Filter

17. Oil Dipstick

18. Oil Drain

19. Control Panel Plug-In

20. Generator Set Plate

21. Expansion Tank

Marine Generator Component Locations

▼

Non-Service Side

22. Wet Exhaust Elbow

23. Junction Box

24. Starter

25. Vibration Mount

26. DC Alternator

Service Side

▼

Figure 2: M843JK, M843NK, service and non-service views

O843K 05/03

8. Lube Oil Drain

9. AC Circuit Breaker

11. Secondary Fuel Filter

12. Crankcase Vent

13. Lube Oil Fill

14. Coolant Fill

15. Injection Pump

16. Fuel Inlet and Return

17. Oil Filter

18. Fuel Lift Pump

19. Block Water Drain

20. Dipstick

1. DC Alternator

2. Exhaust Outlet

3. Air Filter

4. Starter

5. DC Circuit Breaker

6. Generator Junction Box

7. Starter

Industrial Generator Set Component Locations

Non-Service Side

▼

Service Side

▼

Figure 3: NL843NK, service and non-service views

O843K 05/03

Control Panels

Figure 4-B: Series 3 Generator Control Panel

Figure 4-A: Series 1-B Generator Control Panel

Figure 4-C: Series 4 Generator Control Panel

1. SHUTDOWN BYPASS-PREHEAT SWITCH

Two functions are built into this switch: the preheating

of the engine, and bypassing of the engine safety

shutdown circuit. Hold switch in the ON position

10 - 20 seconds before starting the engine, and

continue holding on during engine cranking. Release

the switch as soon as the engine is running. Holding

the switch on too long can burn out the heater element.

2. ENGINE CONTROL SWITCH

To start the engine, hold this switch in the START

position until the engine is running.

NOTE: Excessive cranking of marine sets equipped

with water lift muffler systems can cause engine

damage. See page 10.

After the engine starts, release the switch and it will

return to RUN position. To stop the engine, hold the

switch in the STOP position until the engine has

completely stopped.

NOTE: The rocker switch is used on Series 1 panels

only, and has a light that glows when the set is running.

3. HOUR METER

Keeps track of engine running time.

4. OIL PRESSURE GAUGE

Shows the oil pressure in the engine lubricating system.

5. ENGINE TEMPERATURE GAUGE

Registers the temperature of the engine coolant.

6. D.C. VOLTMETER OR AMMETER

When the engine is stopped, the voltmeter indicates the

condition of the battery. When the engine is running, the

voltmeter indicates the voltage output of the alternator.

For Series 4 Control Panels Only:

7. A.C. VOLTMETER

Shows the generator output voltage.

8. FREQUENCY METER (Hertz)

The frequency meter indicates alternating current

frequency: 60 Hz (1800 RPM), or 50 Hz (1500 RPM).

9. AMMETER/VOLTMETER

SELECTOR SWITCH

Used to check voltage and current of each phase.

10. A.C. AMMETER

Shows the generator load on each phase. The phase is

selected with the Ammeter Selector switch (

Item 9).

O843K 05/03

Control Panels

6. STATUS INDICATOR PANEL

Engine monitoring alarms and lamps for monitoring

engine functions.

7. ALARM LAMP TEST AND RESET BUTTON

Press UP to test the indicator lights and press DOWN

to reset the alarm.

8. AC VOLTAGE ADJUSTMENT RHEOSTAT

Voltage has been set at the factory and should only be

adjusted by factory-trained personnel.

9. AMMETER SELECTOR SWITCH

Used to check each phase for load condition.

NOTE: Always leave this switch in the ON position

while the unit is running.

10. FREQUENCY METER (HERTZ)

The frequency meter indicates alternator current

frequency: 60 Hz (1200 or 1800 RPM), or 50 Hz

(1500 RPM).

11. A.C. VOLTMETER

Shows the generator output voltage.

12. A.C. AMMETER

Shows the generator load on each phase. The phase is

selected with the Ammeter Selector switch.

Figure 5: Series 7.0 through Series 7.6 Generator

Control Panels

1. SHUTDOWN BYPASS SWITCH

Manual Start Panels

(S-7.1 and S-7.3)

Hold the switch in the START position until the engine is

running

NOTE: Excessive cranking may cause engine damage.

After the engine starts, release the switch and it will return

to the RUN position. To stop the engine, hold the switch in

the STOP position.

Auto Start Panels

(S-7.0, S-7.2, S-7.4, S-7.5, and S-7.6)

After the engine starts, release the switch and it will return

to the RUN position. To stop the engine, hold the switch in

the STOP position.

2. OIL PRESSURE GAUGE

Shows the oil pressure in the engine lubricating system.

3. HOUR METER

Keeps track of engine running time.

4. ENGINE TEMPERATURE GAUGE

Registers the temperature of the coolant.

5. DC VOLTMETER

When the engine is running, the voltmeter indicates the

voltage output of the alternator.

O843K 05/03

BREAK-IN PERIOD

1. The first 100 hours on a new or reconditioned

engine are critical to its life and performance.

2. Frequently check the engine temperature and oil

pressure gauges (sets with Series 3 or 4 panels).

3. Oil consumption is greater during break-in as

piston rings take time to seat.

4. Break-In Oil Changes: Change engine oil and

filter at 50 hours. Change oil and filter again at

100 hours (consult Lubricants section for oil

recommendation).

5. Retighten head bolts at 50 hours (see page 13).

Operating Instructions:

Maintain at least a 75% load on your generator

set for the first 100 hours. If this is not possible,

maintain no less than a 50% load to ensure proper

seating of the piston rings. Vary the load to help

seat the rings.

BEFORE STARTING

1. Check the water level by removing the pressure

cap from the expansion tank or radiator. In order to

give the cooling water an opportunity to expand, the

level should be about 1 in. (2.5 cm) below the filler

cap sealing surface when the engine is cold.

CAUTION: Use protective clothing and open

the filler cap carefully when the engine is warm

to prevent burns.

2. Check the oil level in the crankcase with the

dipstick. The oil level must be in the waffled area on

the stick. Never allow the level to go below this area.

Always add the same viscosity of oil as is already in

the crankcase.

3. Check the fuel tank level and open any fuel valves.

4. Marine Sets: close the sea-cock; check, clean, and

reassemble the sea strainer and reopen the sea-cock.

5. Marine Sets: place the battery switch in the ON

position.

6. NOTE: The battery switch must always be kept

ON while the engine is running. If the switch is

turned OFF while the engine is running, the

battery charging regulator could be ruined.

STARTING

1. Hold the Shutdown Bypass-Preheat switch in the

ON position for 10 to 20 seconds before starting a

cold engine. Holding the switch too long can burn

out the glow plugs. This step is not necessary if the

engine is already warm.

2. While holding the Shutdown Bypass-Preheat switch

in the ON position, push the Engine Control switch

to the START position.

3. As soon as the engine starts, release both switches. Do not

crank the starter for more than 20 seconds consecutively.

If the engine fails to start with the first attempt, be sure

that it has stopped completely before re-engaging.

NOTE: Excessive cranking of the starter on Marine

sets equipped with a water lift muffler can cause

engine damage. If the engine does not start after three

20-second cranks, remove the impeller from the raw

water pump. This will prevent the muffler from filling

with water and backfilling the exhaust line and engine.

Once the engine starts, shut it off immediately and

re-install the impeller. Re-start the engine and check

the exhaust overboard outlet for gushes of water.

OPERATING

1. Units with Series 3 and Series 4 Control Panels:

check gauges often. Oil pressure must be above 15

PSI. The D.C. voltmeter should read between 11 and

15 volts at 80°F (25°C) ambient temperature. The

water temperature gauge on Marine sets must be

below 200°F (94°C); on Industrial units the water

temperature gauge must be below 225

F (107

C).

Check the A.C. voltage and frequency meters (Series

4 panel). If the gauges deviate from normal levels,

shut down the generator set and investigate.

2. Let the unit run unloaded for a three to five minute

warm-up period.

3. Apply electrical load.

STOPPING

1. Remove electrical load from the generator set.

2. Run the engine for a 3 to 5 minute cool down period.

3. Hold the Engine Control switch to the STOP

position until the engine comes to a complete stop.

4. Marine Sets: shut off the seacock, fuel valve, and

battery switch.

Operating Procedures

O843K 05/03

SHUTDOWNS AND ALARMS

1. Your unit is fitted with a system to protect it from

high water temperature or low oil pressure.

a. Generator sets have shutdown systems to stop the

engine. They have no warning horns.

b. Other alarms and shutdowns are available as

optional equipment.

NOTE: Do not rely on your warning to the

exclusion of careful gauge monitoring. Watching

your gauges can prevent damage to the unit and

dangerous power losses.

2. Do the following when your warning or shutdown

system is activated:

a. Check the temperature gauge.

Marine sets: If above 205°F (96°C), shut off the

engine immediately.

Industrial sets: If above 230

F (110

C) shut off

the engine immediately.

b. Use the Trouble Shooting Guide on page 22 to

isolate the cause of the overheat.

CAUTION: Do not remove the water fill

cap of an overheated engine. Escaping high

temperature steam can cause severe burns.

Allow the engine to cool and then remove the

cap slowly using protective clothing.

d. Make repairs. Restart your Marine set after the

temperature gauge registers below 200°F (94°C).

e. Watch the temperature gauge regularly and

turn off the unit if the temperature rises

above 205°F (96°C) on Marine units.

Repeat troubleshooting.

3. If shutdown is activated and the temperature gauge

shows temperature within normal temperature range:

a. Check the engine crankcase oil level.

b. If the oil level is low, fill with recommended

lubricating oil and restart. Watch the oil pressure

gauge carefully and shut off the engine if it does

not show a normal reading (20-60 PSI) after a

few seconds of operation.

c. If the oil level is normal, DO NOT restart the

engine. Call your dealer for assistance.

SPARE PARTS

1. ADE recommends that you keep the following spare

parts on hand for field service. The parts are

available from your local Northern Lights dealer.

Some marine models already have “On-Board-Kits,”

a handy box that contains the most common parts

you will need.

2. All owners should have the following spares:

a. Primary and secondary fuel filter elements

b. Oil filters

c. Air filter

d. Alternator belt

e. Thermostat and gaskets

f. Seawater pump impeller & gaskets (marine only)

g. Glow plug

h. Injector and washer

3. If your set is operating a long distance from a

servicing dealer, add the following:

a. Complete set of injectors

b. Copper washers for injector change

c. Complete set of glow plugs

d. Fuel lift pump

Operating Procedures

O843K 05/03

The Servicing Schedule Chart below shows the service schedule required for proper maintenance of your generator set.

More detailed coverage of each Service Point (SP) is listed on the page noted in the ‘page’ column.

DAILY:

SP1 Check oil level in engine

SP7 Check primary fuel filter

SP13 Check cooling water level

Check sea strainer (marine only)

Check raw water pump for leaks

AFTER FIRST 50 HOURS:

SP2/3 Change engine oil and filter

SP5 Check V-belt tension

SP6 Adjust valves

SP18 Check electrolyte in batteries

Retighten head bolts (see page 11)

EVERY 50 HOURS:

SP5 Check V-belt tension

SP18 Check electrolyte in batteries

EVERY 100 HOURS:

SP16 Check and clean radiator (industrial only)

EVERY 200 HOURS:

SP2/3 Change engine oil and filter

SP4 Check air cleaner

SP8 Change primary fuel filter element

SP9 Change secondary fuel filter

EVERY 600 HOURS:

SP6 Check valve clearances

SP11 Check injectors

SP14 Check and flush cooling system

SP17 Change impeller (marine only)

SP19 Check state of charge of batteries

EVERY 2400 HOURS:

SP12 Check fuel injection pump

SP15 Check and clean heat exchanger (marine only)

1) Perform all maintenance once a year even if hour level has not been reached.

2) Consult manufacturer's maintenance schedule, note on chart.

3) Whenever necessary.

4) More often if necessary.

5) After first 50 hours.

Servicing Schedule Chart

SERVICE 50 100 200 600 2400

POINT PAGE OPERATION DAILY Hours Hours Hours Hours Hours

ENGINE:

SP1 8 & 12 Check oil level ●

SP2 12 Change engine oil 1) 5) ●

SP3 12 Change lube oil filters 1) 5) ●

SP4 12 Check air cleaner 1) 4) ●

SP5 12 Check V-belt tension 1) 4) ●

SP6 13 Check valve clearances 1) 2) 5) ●

FUEL SYSTEM:

SP7 14 Check primary filter (Racor) 2) 3) ●

SP8 14 Change primary filter element (Racor) 2) 3) ●

SP9 14 Change secondary fuel filter 1) 3) ●

SP10 15 Bleed the fuel system 3)

SP11 16 - 17 Check injectors 1) 3) ●

SP12 17 Check fuel injection pump ●

COOLING SYSTEM:

SP13 8 & 17 Check cooling water level ●

SP14 17 - 18 Check and flush cooling system ●

SP15 18 Check and clean heat exchanger (Marine) ●

SP16 - Check and clean radiator fins (Industrial) ●

SP17 18 Change impeller in raw water pump 1) 3) ●

SP21 Inspect condition of exhaust elbow 4) ●

ELECTRICAL SYSTEM:

SP18 19 Check electrolyte level in batteries 1) 4) ●

SP19 19 Check condition of batteries with hydrometer 1) 4) ●

DRIVEN EQUIPMENT:

SP20 19 Clutch and PTO service (M843NK only) 2)

OUT OF SERVICE:

SP21 19 Winterizing or out-of-service 3)

O843K 05/03

50 HOURS

SP5 Check V-belt tension

SP18 Check electrolyte in batteries

100 HOURS

SP3 Change lubricating oil filters

SP4 Check air cleaner

SP16 Check and clean radiator

EVERY 200 HOURS

SP2 Change engine oil and filter

SP8 Change primary filter element (Racor)

SP9 Change secondary fuel filter

SP21 Inspect condition of exhaust elbow

EVERY 600 HOURS

SP6 Check valve clearances

SP11 Check injectors

SP14 Check and flush cooling system

SP17 Change impeller in raw water pump

SP19 Check condition of batteries with hydrometer

2400 HOURS

SP12 Check fuel injection pump

SP15 Check and clean heat exchanger

Service

Point

HOURS/DATE

Service Record

OPERATION

O843K 05/03

Servicing

LUBRICATION - GENERAL

1. Use only clean, high quality lubricants stored in

clean containers in a protected area.

2. These lubricants are acceptable:

a. API Service CC/CD/CE single viscosity oils.

b. API Service CC/CD/SF multi-viscosity oils.

3. Use the proper weight oil for your average operation

temperature.

Figure 6: Lube Oils

4. Some increase in oil consumption may be expected

when SAE 5W and SAE 5-20W oils are used. Check

oil level frequently.

5. Never put additives or flushing oil in crankcase.

SP1. CHECKING OIL LEVEL

1. Check the oil level in the crankcase with the

dipstick. The oil level must be in the waffled area

on the stick. Never allow the level to go below this

area. Follow the lubrication recommendations above.

SP2. OIL CHANGES

1. The set is delivered with special break-in oil.

Change the engine oil and oil filter after 50 hours

of operation. Use Service CC 30 weight oil during

the first 100 hours.

2. Change the oil and filter again at 100 hours using the

oil recommended in the above diagram. After this,

change oil and filter every 200 hours.

3. During intermittent cold weather operation, change

oil every 100 hours or six weeks, whichever comes

first.

4. Change oil at the end of each season and the

beginning of each season.

5. Change oil when engine is warm.

6. Dispose of waste oil in an approved manner.

7. Never use a flushing oil.

8. Loosen the clamp on the oil change tube. Remove

cap. Drain oil. Replace the cap and tube.

9. Refill engine with recommended oil for the season.

10. Engine capacity with new oil filter is:

843JK and 843NK – 5.8 quarts (5.5 liters)

SP3. CHANGING LUBE OIL FILTER

1. Change the lube oil filter every 200 hours.

2. Use a filter wrench to remove old filter. Dispose of

filter in approved manner.

3. Make sure the gasket from the old filter is removed

and discarded. Clean mount face.

4. Spread a thin film of engine oil on the rubber gasket

on the new filter and screw it on nipple until gasket

meets the sealing surface.

5. Using hands only – no wrench – tighten filter

one-half turn farther. Overtightening can do

damage to filter housing.

6. Fill engine with recommended oil. Start engine and

check for leakage. Stop engine, wait 3 minutes, and

check oil level. Add additional oil if necessary.

7. Oil filter part number is:

843JK and 843NK – #24-03100

Air Single Multi-

Temperature Viscosity Viscosity

Above 32°F

SAE 30W SAE 15-40W

(0°C)

-10 to 32°F

SAE 10W SAE 10-30W

(-23 to 0°C)

Below -10°F

SAE 5W SAE 5-20W

(-23°C)

O843K 05/03

SP4. AIR CLEANER

1. Inspect air cleaner every 200 hours. In dusty

conditions, check more often.

2. Marine sets: if dirty, wash element in soapy water.

Rinse and dry thoroughly before re-installing.

Replace if necessary. Part numbers are:

M843JK and M843NK – #24-23100

3. Industrial sets: the element cannot be cleaned.

Replace it when necessary. Part number is:

NL843NK – #314531127

4. NOTE: Make absolutely sure no impurities enter

the engine while changing the element. Do NOT

run the engine with the air cleaner removed.

SP5. V-BELTS

1. Check the tension and wear on the V-belt after

every 50 hours.

2. Use your thumb to press on the belt at the midpoint

between the crankshaft and alternator pulleys. The

tension is correct if the belt can be depressed about

3/16 in. (5 mm).

RETIGHTENING CYLINDER HEAD BOLTS

1. Tighten bolts when the engine is cold.

2. Loosen the nuts and remove rocker arm cover.

3. Tighten head bolts with a torque wrench in the order

shown in figures below. Tighten bolts evenly in 2 or

3 passes, ending at the specified torque in final pass.

843JK & 843NK: 60 - 64 ft/lbs (9.0 - 9.5 kg/m)

Servicing

Figure 7: 843N Head Torque Sequence

Figure 8: Valve Adjustment

SP6. VALVE CLEARANCES

1. Adjust valve clearance after first 50 hours of

operation and every 600 hours thereafter.

2. Valve adjustments should be done after the cylinder

head bolts have been re-tightened. Engine should be

cold and NOT running.

3. Watch the valves while turning the engine over by

hand. Turn until the inlet valve starts to open and the

exhaust valve starts to close (the valves are rocking).

Then turn the crankshaft one more full turn and

adjust the clearance on both valves for this cylinder.

4. Loosen the lock nut and adjust the clearance

between the rocker arm and valve guide of both the

intake and exhaust valves with the adjustment screw

(Figure 8). Clearance on both intake and exhaust

valves should be 0.008 in. (0.2 mm).

5. Repeat steps 3 and 4 for each cylinder. Each set of

valves must be adjusted individually.

6. Replace the rocker arm cover. Tighten cover nuts to

5 - 8 ft/lbs (0.8 - 2.3 kg/m).

Valve Adjustment Screw

Rocker Arm

0.008 in.

0.200 mm.

O843K 05/03

Servicing

FUELS - GENERAL

1. Use only clean, high quality fuels of the following

specifications, as defined by ASTM designation

D975 for diesel fuels:

a. Use grade no. 2 diesel at ambient temperatures

above freezing 32°F (0°C).

b. Use grade no. 1 at ambient temperatures below

freezing and for all temperatures at an altitude of

above 5,500 ft. (1500 meters).

2. Use fuel having less that 1% sulphur (preferably less

that 0.5%).

3. The cetane number should be a minimum of 45.

4. DO NOT use these unsuitable grades of fuel:

a. Domestic heating oils, all types.

b. Class B engine.

c. Class D domestic fuels.

d. Class E, F, G or H industrial or marine fuels.

e. ASTM-D975-60T No. 4-D and higher number

fuels.

5. Storing fuel:

a. Keep dirt, scale, water, and other foreign matter

out of fuel.

b. Avoid storing fuel for long periods of time.

c. Fill the fuel tank at the end of each day’s

operation. This will reduce condensation and

possible biological contamination.

d. If biological contamination is detected or

suspected, contact your dealer for assistance.

SP7-9. FUEL FILTERS

1. Your generator set should have a primary fuel filter

installed. We recommend the Racor brand of fuel

filter-water separators.

a. Check the primary fuel filter daily as

recommended by the filter manufacturer.

Empty the collection bowl as necessary.

b. Change the element as often as necessary or

every 200 hours.

c. If the bowl fills with water, change the primary

and secondary element immediately.

2. Change secondary fuel filter every 200 hours.

NOTE: The fuel filter on the engine is considered the

“secondary fuel filter.”

a. Remove the spin-on filter by turning it

counterclockwise with a filter wrench. Fill the

new cartridge with fuel and install it after

applying engine oil to gasket surface. Screw on

until the gasket surface comes into contact with

sealing surface of filter base. Then, tighten it

two-thirds of a turn by hand. Do not overtighten.

b. Fuel filter part numbers are:

843JK and 843NK – #130336020

O843K 05/03

Servicing

SP10. BLEEDING THE FUEL SYSTEM

CAUTION: Escaping diesel fuel under pressure can penetrate skin causing serious personal injury.

Before disconnecting lines be sure to relieve all pressure. Before applying pressure, be sure all connections

are tight and lines, pipes and hoses aren't damaged. Fuel escaping from a very small hole can be almost

invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks. If injured by

escaping fuel, see a doctor at once. Serious infection or reaction can develop if proper medical treatment

isn't administered immediately.

Figure 9: NL843NK Fuel System.

1. The fuel system is self-bleeding. However, any

system may need manual bleeding when:

a. A new fuel filter is installed;

b. The engine has run out of fuel;

c. The fuel lines, injection pump or any other fuel

system component has been removed and

installed.

2. Loosen bleed bolt “A” (Figure 9) on top of the filter.

Pump hand primer “B” on fuel lift pump until pure

fuel (no bubbles) escapes from bleed bolt “A”.

Tighten bleed screw “A”.

3. Loosen bleed screw “C”. Pump hand primer “B”

until pure fuel (no bubbles) escapes. Then tighten

bleed screw “C”.

4. If the engine does not start after the above bleeding

process, loosen a fuel line at the injector while

cranking the engine with the starter motor until pure

fuel escapes. Then tighten the connection. Do each

line one-at-a-time.

5. After the engine has started, use a piece of cardboard

to look for fuel leaks.

O843K 05/03

Figure 10: Remove delivery line flare nuts.

Figure 11: Remove delivery lines.

Figure 12: Cover lines, inlets and injection pump outlets.

Figure 14: Remove return line.

Figure 15: Unscrew injector.

Figure 16: Remove and replace copper sealing washer.

Figure 17: Reinstall injector. Torque to proper tightness.

Servicing

Figure 13: Remove return line nuts.

O843K 05/03

SP11. INJECTOR SERVICE

1. Injectors should be checked every 600 hours. Check

should be made by a Northern Lights dealer or local

injection repair station.

CAUTION: Escaping diesel fuel under pressure

can have sufficient force to penetrate the skin

causing serious personal injury. If injured by

escaping diesel fuel, see a doctor at once.

2. Injector removal:

a. Clean loose dirt from around the injectors and

the fuel lines.

b. Relieve high pressure in the fuel lines by

loosening the delivery line flare nuts at each

injector (Figure 10).

c. Remove delivery lines by disconnecting from

injectors and injection pump (Figure 11). Remove

all lines as an assembly; do not remove the spacers.

Cover the ends of the lines, the injector inlets and

injection pump outlets to keep dirt out (Figure 12).

d. Remove the return line retaining bolts (Figure 13).

Remove the return line (Figure 14).

e. Unscrew and remove the injectors (Figure 15).

NOTE: Do not use pry bars to remove injectors

from cylinder head.

f. After removing the injectors, discard the copper

sealing washers from the injector hole in the head

(Figure 16). Cover holes to prevent dirt and debris

from entering the cylinders.

3. Injector installation:

a. Install a new copper sealing washer in each

injector hole (Figure 16).

b. Screw in injector and tighten to 44 - 51 ft/lbs

(6 to 7 kgm) (Figure 17).

NOTE: Overtightening can damage injector.

c. Install return line using a new sealing washer

below each connection. Tighten return line

retaining bolts to 22 - 30 ft/lbs.

d. Install delivery lines. Leave loose at injectors for

bleeding.

e. Crank engine to fill lines. Tighten lines at

injectors to 11-18 ft./lbs. Start engine and check

for leaks using a piece of paper or cardboard.

DO NOT use hand to check for leaks.

SP12. INJECTION PUMP

1. Since operating conditions may vary considerably, it

is difficult to give a definite interval for checking the

injection pump. But as a rule, pump settings,

maximum speed, idle speed and exhaust smoke

should be checked after every 2400 hours of

operation. Service of the fuel injection pump should

only be done if checks indicate pump malfunction.

2. Black smoke can be an indication of pump

malfunction. Before servicing the pump, check other

possible causes:

a. Check cleanliness of air filter.

b. Check valve clearances.

c. Clean and check injectors.

3. Any repair which involves disassembly of the

injection pump must be carried out by specially

trained mechanics with the proper tools and test

equipment.

NOTE: All warranties on the engine become null

and void if the injection pump seals are broken by

unauthorized persons.

COOLING SYSTEM - GENERAL

NOTE: Marine sets – be sure to close the sea-cock

before working on the engine cooling system.

CAUTION: The cooling water in the engine

reaches extremely high temperatures. You must

use extreme caution when working on hot

engines to avoid burns. Allow the engine to cool

before working on the cooling system. Open the

filler cap carefully, using protective clothing

when the engine is warm.

SP13. CHECK THE COOLANT LEVEL

1. Check the coolant level each day before starting the

engine. Check the water level by removing the

pressure cap from the expansion tank.

In order to give the cooling water an opportunity to

expand, the level should be about 1 in. (2.5 cm) below

the filler cap sealing surface when the engine is cold.

2. The pressure valve in the filler cap releases when the

pressure is approximately 7 PSI (0.5 bar). Use a cap

pressure tester to check cap if you suspect it is faulty.

Servicing

O843K 05/03

Servicing

SP14. COOLING SYSTEM FLUSHING

1. Flush the cooling system every 600 hours or every

12 months, whichever comes first.

2. Marine sets:

a. Remove expansion tank cap and drain engine

block.

b. Open block drain cock. Remove hose from

bottom of heat exchanger tank.

c. Pour clean water into expansion tank until water

coming from drains is free of discoloration and

sediment. Let water drain completely. Close

drains and refill with recommended mixture.

3. Industrial sets:

Remove radiator cap and open drain cocks on

radiator and engine block. Pour clean water into

radiator until water coming from radiator is clear of

discoloration. Close the radiator drain and continue

flushing until water from engine drain is clear. Open

all drain cocks and drain completely. Close drain

cock and refill with recommended coolant mixture.

Clean fins on radiator.

3. Coolant Specifications (marine and industrial):

Use 50% distilled water / 50% ethylene glycol

antifreeze mix. Antifreeze mixture is recommended

as a good year-round coolant.

4. Check hoses and connections and repair any leakage.

SP15. HEAT EXCHANGER (Marine)

1. Clean the heat exchanger core once a year or after

2400 hours of operation.

2. Drain expansion tank and heat exchanger.

3. Remove heat exchanger end covers and remove

core.

4. Clean the inside of exchanger core tubes using

a metal rod. Flush, inspect and clean again if

necessary.

5. Reassemble. Fill the cooling system, start the engine

and check for leaks.

SP16. CLEAN RADIATOR (Industrial)

1. Remove debris from radiator fins daily.

2. In very dusty applications, clean the radiator with

compressed air or steam cleaner every 100 hours.

Clean in the reverse direction of the airflow.

SP17. RAW WATER PUMP (Marine)

1. Change the seawater pump impeller every 600

hours, or as needed.

2. Remove the pump end cover. Pry out the impeller

using needle-nose pliers or two screwdrivers.

Be sure you remove all pieces of failed impeller.

NOTE: Place some kind of protection under the

screwdrivers in order not to damage the pump

housing. If the impeller has broken into pieces,

remove front heat exchanger end cover and inspect

for impeller pieces. Clean inlet to heat exchanger

bundle and reassemble.

3. Clean the inside of the housing.

4. Press in the new impeller and place the sealing

washers in the outer end of the impeller center if this

has not already been done.

5. Replace the cover using a new gasket.

NOTE: Make sure that there is always an extra

impeller and cover gasket in reserve on board.

GENERATOR ENDS

The maintenance and operation recommendations

for the generator end are in a separate Owner’s

Manual. If you do not have one of these manuals,

contact your local Northern Lights dealer.

ELECTRICAL SYSTEM - GENERAL

1. Never switch battery switch off or break the circuit

between the alternator and batteries while the engine

is running. Regulator damage can result.

2. Do NOT reverse the polarity of battery cables when

installing the battery.

3. If welding on the unit, disconnect the regulator and

battery. Isolate the leads.

4. Disconnect the battery cables when servicing the

D.C. alternator.

5. Never test with a screwdriver, etc., against any

terminal to see if it emits sparks.

6. Do not polarize the alternator or regulator.

7. A D.C. circuit breaker protects your control panel

and wiring harness. It is located in the side of the

generator junction box.

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Nothern Lights M843JK User manual

Brand: Nothern Lights

Model: M843JK

Category: Power generators

Type: User manual

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